Cellucotton Having Vertical Structure That Enables Bi-Directional Elasticity, Production Device and Method Thereof

ABSTRACT

A cellucotton having a vertical structure that enables bi-directional elasticity, a production device and a method thereof are disclosed. During the production of the cellucotton having a vertical structure by lapping and stacking of fiber layers ( 3 ), multiple gaps are created in the longitudinal direction along the fiber layers, thereby enabling elasticity in the longitudinal direction; and disposed on the cellucotton having a vertical structure produced by lapping and stacking on the fiber layer are multiple fiber grooves ( 31 ), the fiber grooves enable elasticity in the transverse direction. The cellucotton has good elasticity in the longitudinal and transverse directions, and can therefore be used for car seat cushions, sofas, and women&#39;s underwear to avoid deformation arising from unidirectional expansions and contractions.

CROSS REFERENCE OF RELATED APPLICATION

This is a a national phase national application of an international patent application number PCT/CN2011/081644 with a filing date of Nov. 1, 2011 based on a foreign application number 201010532279.X with a filing date of Nov. 3, 2010 in China. The contents of these specifications, including any intervening amendments thereto, are incorporated herein by reference.

BACKGROUND OF THE PRESENT INVENTION

1. Field of Invention

The present invention relates to the technical field of cellucotton, and more particularly to a cellucotton having a vertical structure that enables bi-direction elasticity and manufacturing method thereof.

2. Description of Related Arts

Cellucotton having a vertical structure, which has a good elasticity and low manufacturing costs, has been widely used. For example, manufacturing car seat cushions, sofas in the car industry, or the like.

A conventional cellucotton having a vertical structure is manufactured by forming a plurality of fiber layers by a plurality of short and small fibers via a cotton carding machine and stacking the fiber layers. Because the fibers layers and fibers are wavy shaped in the stacking direction of the cellucotton of this type of structure, so that the cellucotton has a good elasticity in the stacking direction, i.e. the longitudinal direction. However, the densities of the fibers are evenly distributed in the transverse direction, thus the cellucotton substantially has no elastic flexibility in the transverse direction.

SUMMARY OF THE PRESENT INVENTION

The main technical problem to be solved of the present invention is to provide a cellucotton having a vertical structure that enables bi-direction elasticity, a production device and a manufacturing method thereof, wherein the cellucotton has flexibility in both orthogonal directions and thus has better elasticity.

Additional advantages and features of the invention will become apparent from the description which follows, and may be realized by means of the instrumentalities and combinations particular point out in the appended claims.

According to the present invention, the foregoing and other objects and advantages are attained by a cellucotton having a vertical structure that enables bi-directional elasticity, the cellucotton comprises stacked fiber layers having a same thickness, wherein fibers of each of the fiber layers are carded to align in a same direction via a cotton carding machine, wherein the cellucotton having a vertical structure is respectively provided with gaps, and fiber grooves or fiber gaps in longitudinal direction and transverse direction by net forming or lapping and stacking process.

Preferably, the fiber grooves or fiber gaps are evenly distributed in the fiber layers, and adjacent the fiber grooves or fiber gaps are parallel to each other.

Preferably, the doffer comprises at least two card clothing structures on an outer surface thereof, wherein the card clothing structure comprises at least one card cloth, wherein when the card clothing structure comprises at least two card clothing structures, the at least two card clothes are evenly distributed along a circle.

Preferably, card clothing structures are evenly arranged in an axial direction of the doffer.

The present invention further provides a production device for manufacturing the cellucotton having a vertical structure that enables bi-directional elasticity, wherein the production device for manufacturing the cellucotton having a vertical structure comprises a cylinder and a doffer, wherein the doffer comprises at least two card clothing structures on an outer surface thereof, wherein the card clothing structure comprises at least one card cloth, wherein when the card clothing structure comprises at least two card clothing structures, the at least two card clothes are evenly distributed along a circle.

Preferably, the barb structures are evenly arranged in an axial direction of the doffer

The present invention further provides a production device for manufacturing the cellucotton having a vertical structure that enables bi-directional elasticity, wherein the production device for manufacturing the cellucotton having a vertical structure comprises a cotton carding machine, wherein two roller couples are provided at an exit of the cotton carding machine, wherein one of the roller couples is provided with at least two parallel barb structures on an outer surface thereof, wherein the barb structure comprises at least one barb, wherein when the barb structure comprises at least two barb structures, the at least two barbs are evenly arranged along a circle.

Preferably, the barb structures are evenly arranged in an axial direction of the doffer.

The present invention further provides a method for manufacturing the cellucotton having a vertical structure that enables bi-directional elasticity, wherein the method comprises the following steps:

Carding fibers to from fiber layers with fibers arranged in one single direction;

Forming fiber grooves or fiber gaps in a length direction of the fiber layers;

Lapping, stacking, and shaping the fiber layers provided with the fiber grooves or fiber gaps.

Preferably, the step of forming fiber grooves or fiber gaps in a length direction of the fiber layers comprising the step of cotton picking of the fiber layers in such a manner that the fiber grooves or the fiber gaps which have smaller fiber density and thickness than other location of the fiber layers are formed on cotton picking locations.

Preferably, the fiber grooves or the fiber gaps have smaller fiber density and thickness than other location of the fiber layers.

The present invention provides a cellucotton having a vertical structure that enables bi-directional elasticity, a production device and a method thereof. During the production of the cellucotton having a vertical structure by lapping and stacking of fiber layers, multiple gaps are created in the longitudinal direction along the fiber layers, thereby enabling elasticity in the longitudinal direction; and the cellucotton having a vertical structure produced by lapping and stacking on the fiber layer are provided with multiple fiber grooves (or fiber gaps), the fiber grooves (or fiber gaps) enable elasticity in the transverse direction. The cellucotton has good elasticity in the longitudinal and transverse directions, and can therefore be used for car seat cushions, sofas, and women's underwear such as brassiere lining to avoid deformation arising from unidirectional expansions and contractions.

Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.

These and other objectives, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a schematic view of the fiber layer according to a preferred embodiment of the present invention.

FIG. 1 b is a sectional view of the fiber layer along A-A line according to the above preferred embodiment of the present invention.

FIG. 2 is schematic view of the production device of the cellucotton having a vertical structure according to a preferred embodiment of the present invention.

FIG. 3 is schematic view of the doffer according to the above preferred embodiment of the present invention.

FIG. 4 is a schematic view of an alternative mode of the production device of the cellucotton having a vertical structure according to the above preferred embodiment of the present invention.

FIG. 5 is a flow chart illustrating the manufacturing method of the cellucotton having a vertical structure according to a preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

As shown in FIGS. 1 a and 1 b, the present invention provides a cellucotton having a vertical structure that enables bi-directional elasticity.

In the cellucotton having a vertical structure that enables bi-directional elasticity, fibers are carded in a same direction via a cotton carding machine and stacked with fiber layers 3 having even thicknesses. In a direction along the fibers of the fiber layers 3 of the cellucotton, i.e the longitudinal direction of the fiber layer 3, there is provided with a corrugated shaped configuration formed by fibers grooves 31 (or fiber gaps) which have smaller fiber densities and thicknesses than other locations of the fiber layer 3. The fiber grooves 31 can be evenly disturbed in the fiber layer 3 with adjacent fiber grooves 31 (or fibers gaps) are parallel to each other. The bi-direction is referred to two orthogonal directions. For example, when the cellucotton having a vertical structure in the plane coordinate system has best elasticity in X-axis direction (i.e. the stacking direction of the cellucotton having a vertical structure or the direction of the fiber grooves 31) and Y-axis direction (i.e. the vertical direction with respect to the stacking direction of the cellucotton having a vertical structure or the direction of the fiber grooves 31). There is elasticity along any other direction but is relatively weaker than the elasticity in the X-axis direction and Y-axis direction.

Because when the cellucotton having a vertical structure is formed by lapping and stacking on the fiber layers 3, there is elasticity in the length direction of the fiber layers, i.e the fiber grooves 31 (or fiber gaps) in the longitudinal direction of the fiber layers 3 enable elasticity in the longitudinal direction of the cellucotton. In other words, the cellucotton has elasticity in a vertical direction with respect to the fiber grooves 31 (or fiber gaps). At the same time, during lapping and stacking of the fiber layers 3, gaps are created in the longitudinal direction of the cellucotton. The gaps enable the cellucotton having elasticity in the stacking direction of the fiber layers 3, i.e. vertical direction with respect to the gaps. Because the cellucotton of this structure has good bi- directional elasticity, it can be widely used for car seat cushions, sofas, as well as female underwear such as brassiere lining. Therefore, the deformation arising from unidirectional elasticity is prevented.

Referring to FIGS. 2 and 3, another object of the present invention is to provide a production device for manufacturing the cellucotton having a vertical structure that enables bi-directional elasticity.

The production device for manufacturing the cellucotton having a vertical structure that enables bi-directional elasticity comprises: a cylinder 1 and a doffer 2. The doffer 2 comprises a card clothing structure 21 on an outer surface thereof. The card clothing structure 21 comprises a plurality of card clothes which are evenly and circularly distributed. The number of the card clothes can be adjusted according to practical requirements, such as one, two or more. When the card clothing structure 21 comprises at least two card clothes, the at least two card clothes are evenly distributed along a circle. The number of the card clothing structure 21 can be adjusted according to practical requirements, such as one group, two or more groups. When the number of the card clothing structure 21 is two or more groups, the card clothing structures 21 are respectively parallel to each other. The axial distance of each group of the card clothing structure 21 along the doffer 2, which is a distance between the card clothing structures 21, can be adjusted according to practical requirements. The smaller the distance between the card clothing structures 21, the more the fiber grooves 31 (or fiber gaps) formed in the fiber layers 3, and the formed cellucotton will have more elasticity in that direction. Other structures, forming process and configuration are same to the prior art and thus are eliminated in the present disclosure.

When the doffer 2 is in operation, only the doffer 2 wrapped with the card clothing structures 21 is capable of stripping the fiber layers 3 on the cylinder 1. The gap between the card clothing structures 21 and the gap between the card clothes cannot strip the fiber layers 3 on the cylinder 1, so that fiber layers 3 with transverse fiber grooves (or fiber gaps) are obtained. The fiber layers 3 are then used for manufacturing the cellucotton having a vertical structure via a vertical cotton carding system. Because the cellucotton has fiber grooves (or fiber gaps) both in longitudinal and transverse directions, so that bi-directional elasticity is provided. According to this preferred embodiment, the distances of the card clothing structures 21 on the doffer 2 in the axial direction are the same, i.e. the distances between each group of the card clothing structures 21 are the same, the distance of the fiber grooves 31 (or fiber gaps) formed in the fiber layers are thus the same. Therefore, the cellucotton manufactured by the fiber layers has evenly distributed elasticity in the vertical direction with respect to the fiber grooves 31 (or fiber gaps).

As shown in FIG. 4, the present invention further provides another production device for manufacturing the cellucotton having a vertical structure that enables bi-directional elasticity.

The production device for manufacturing the cellucotton having a vertical structure that enables bi-directional elasticity comprises cotton carding machine 1′ and two roller couples 4 which are provided at an exit of the cotton carding machine 1′. One of the roller couples 4 is provided with a plurality of parallel barb structures 41 on an outer surface thereof. The barbs of each group of the barb structures 42 are arranged along a circle. Other structures of this preferred embodiment is the same with the structures of the above preferred embodiment and thus are eliminated. Preferably, the barb structures 41 have same axial distances between the roller couples 4.

After normal fiber layers 3 are carded out from the cotton carding machine 1′, the fiber layers 3 then pass through between the two roller couples 4. Because one of the roller couples 4 is provided with barb structures 41, so that a portion of the fibers are taken away and thus fiber grooves 31 (or fiber gaps) are formed in the fiber layers 3 in the transverse direction. The fiber layers 3 are then used for manufacturing the cellucotton having a vertical structure via a vertical cotton carding system. Because the cellucotton has fiber grooves (or fiber gaps) both in longitudinal and transverse directions, so that bi-directional elasticity is provided.

As shown in FIG. 5, another object of the present invention is to provide a method for manufacturing the cellucotton having a vertical structure that enables bi-directional elasticity from short fibers.

The method for manufacturing the cellucotton having a vertical structure that enables bi-directional elasticity comprises the following steps.

Step S10: a cotton carding step. The fibers are carded to form fiber layers with the fibers provided along one single direction. More specifically, the fibers undergoing a cotton carding treatment via a cotton carding machine. Especially the short fibers are provided with a cotton carding treatment to form fiber layers with the fibers provided along one single direction.

Step S11: a cotton picking step. More specifically, picking the fiber layers from the step S10 in such a manner that fiber grooves or fiber gaps are formed in the length direction of the fiber layers. For example, the doffer 2 according to the above preferred embodiment can be employed. When the doffer 2 is in operation, only the doffer 2 wrapped with the card clothing structures 21 is capable of stripping the fiber layers 3 on the cylinder 1. The gap between the card clothing structures 21 and the gap between the card clothes cannot strip the fiber layers 3 on the cylinder 1, so that fiber layers 3 with transverse fiber grooves (or fiber gaps) are obtained. Therefore, the cellucotton has elasticity in the transverse direction with the actions of the fiber grooves (or fiber gaps).

The fiber layers 3 also can pass through between the two roller couples 4.

Because one of the roller couples 4 is provided with a plurality of parallel barb structures 41 on an outer surface thereof, the barbs of each group of the barb structures 42 are arranged along a circle, and the barb structures 41 have same axial distances between the roller couples 4. A portion of the fibers are taken away and thus fiber grooves 31 (or fiber gaps) are formed in the fiber layers 3 in the transverse direction. Because the fiber layers 3 with the fiber grooves 31 (or fiber gaps) are used for forming the cellucotton having a vertical structure, the fiber layers have transverse elasticity in the vertical direction with respect to the fiber grooves 31 (or fiber gaps).

Step S12: a lapping and stacking shaping step. The fiber layers provided with fiber grooves or fiber gaps are lapped, stacked and formed in shape in the longitudinal direction. In other words, the fiber layers which has undergoing the cotton picking step in the Step S11 is lapped and stacked in such a manner that the fiber layers are stacked and shaped to form a bulk cellucotton with a predetermined thickness and length. Because when the fiber layers are stacked to from the cellucotton having a vertical structure, gaps are created in the length direction of the fibers layers and thus the gaps enables elasticity in the longitudinal direction of the cellucotton. Therefore, the cellucotton formed by lapping and stacking of the fiber layers have elasticity both in longitudinal direction and transverse directions, and can therefore be used for car seat cushions, sofas, and women's underwear such as brassiere lining to avoid deformation arising from unidirectional expansions and contractions.

One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.

It will thus be seen that the objects of the present invention have been fully and effectively accomplished. It embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims. 

1. A cellucotton having a vertical structure that enables bi-directional elasticity, comprising stacked fiber layers having a same thickness, wherein fibers of each of said fiber layers are carded to align in a same direction via a cotton carding machine, characterized in that said cellucotton having a vertical structure is respectively provided with gaps, and fiber grooves or fiber gaps in longitudinal direction and transverse direction by net forming or lapping and stacking process.
 2. The cellucotton having a vertical structure that enables bi-directional elasticity according to claim 1, characterized in that said fiber grooves or fiber gaps are evenly distributed in the fiber layers, and adjacent said fiber grooves or fiber gaps are parallel to each other.
 3. A production device for manufacturing the cellucotton having a vertical structure that enables bi-directional elasticity comprising a cylinder and a doffer, characterized in that said doffer comprises at least two card clothing structures on an outer surface thereof, wherein said card clothing structure comprises at least one card cloth, wherein when said card clothing structure comprises at least two card clothing structures, said at least two card clothes are evenly distributed along a circle.
 4. The production device for manufacturing the cellucotton having a vertical structure that enables bi-directional elasticity according to claim 3, characterized in that said card clothing structures are evenly arranged in an axial direction of said doffer.
 5. A production device for manufacturing the cellucotton having a vertical structure that enables bi-directional elasticity comprising a cotton carding machine, characterized in that two roller couples are provided at an exit of said cotton carding machine, wherein one of said roller couples is provided with at least two parallel barb structures on an outer surface thereof, wherein said barb structure comprises at least one barb, wherein when said barb structure comprises at least two barb structures, said at least two barbs are evenly arranged along a circle.
 6. The production device for manufacturing the cellucotton having a vertical structure that enables bi-directional elasticity according to claim 5, characterized in that said barb structures are evenly arranged in an axial direction of said doffer.
 7. A method for manufacturing the cellucotton having a vertical structure that enables bi-directional elasticity, characterized in that the method comprising the following steps: carding fibers to from fiber layers with fibers arranged in one single direction; forming fiber grooves or fiber gaps in a length direction of said fiber layers; and lapping, stacking, and shaping said fiber layers provided with said fiber grooves or fiber gaps.
 8. The method for manufacturing the cellucotton having a vertical structure that enables bi-directional elasticity according to claim 7, characterized in that the step of forming fiber grooves or fiber gaps in a length direction of said fiber layers comprising the step of cotton picking of said fiber layers in such a manner that said fiber grooves or said fiber gaps which have smaller fiber density and thickness than other location of said fiber layers are formed on cotton picking locations.
 9. The method for manufacturing the cellucotton having a vertical structure that enables bi-directional elasticity according to claim 7, characterized in that said fiber grooves or said fiber gaps have smaller fiber density and thickness than other location of said fiber layers.
 10. The method for manufacturing the cellucotton having a vertical structure that enables bi-directional elasticity according to claim 8, characterized in that said fiber grooves or said fiber gaps have smaller fiber density and thickness than other location of said fiber layers. 